Soil Waste Design Installation Manual PDF
Soil Waste Design Installation Manual PDF
Soil Waste Design Installation Manual PDF
Waste
Design & installation
Now includes:
• PVCu
• dBlue
• HDPE
marley.co.uk
MARLEY AKATHERM HDPE |
Innovation & Expertise Marley Soil & Waste systems
BS EN ISO 9001:2008
BS EN ISO 14001:2004
Contents
4 PVCu soil & waste systems 18 Marley dBlue
5 Commercial applications 19 Pipe support system
6 Key components 20 Boss branches
20 Boss pipe connections
Design
21 WC connections
8 Stack design
22 WC manifold system
11 Design of waste systems
23 Site work
12 Waste traps
24 HDPE jointing methods
12 WC manifold system
31 HDPE installation
14 Durgo air admittance valve
35 HDPE handling and storage
15 Fire protection
36 British & European Standards
Installation 37 Marley system solutions
16 PVCu jointing techniques
17 Pipe support
Weathering slate
SAS45
●● 8
2, 110 and 160mm push-fit and solvent Marley Akatherm HDPE
weld soil systems incorporating socketed Pipe clip The Marley Akatherm HDPE drainage range is
and plain ended pipe SC45
certified to BS EN 1519: 2000 (licence number
●● 1
10mm WC connectors for all BS WC pans. Pipe
Pipe KM 545820) An extension of the Marley soil
KP204
SL403 & waste portfolio, the HDPE range offers an
Available with solvent weld or push-fit joints.
alternative solution to cast iron.
●● 1
10mm WC manifold system allows ranges Branch
SY401 It is particularly suited for commercial
of toilets to be connected horizontally. applications or where a product with high
Ideal for commercial applications. Bent pan connector impact or abrasion resistance is required,
SWCB90 45° tee
●● 5
0 and 82mm floor outlet components KT21
such as hospitals, hotels, schools, as well as
residential buildings. HDPE will also cope with
are available as separate components or Boss connector temperature variations of -40°C to 100°C.
as an all in one trapped floor outlet. SA421
The combination of the excellent material
●● F ire sleeves and pipe wraps, providing Collar boss
SCB41 properties of HDPE with homogenous welded
up to 4 hours rating. joints provides greater installation flexibility
with a wide range of jointing options
●● 1
10 and 160mm pipe support
components designed specifically to Low level bath trap
P5040
meet the needs of supporting horizontal
or vertical suspended PVCu pipework. P trap
P040
●● 8
2, 110 and 160mm pipes and fittings are
also suitable for use as internal and external Waste pipe Key fitting: Akavent aerator
rainwater pipes to drain flat roofs and The need for secondary venting in high-rise The unique shape of the fitting increases
metal gutter systems on commercial and Boss connector
buildings can be eliminated with the Akavent the capacity of the stack. The soil and
Boss pipe SA421 aerator. An Akavent aerator fitting breaks the waste flow from the higher floors smoothly
industrial buildings.
SW40 fall on each floor and as a consequence the converges with the flow of the lower floor.
secondary vent pipe is not required as the
Pipe
SP403
pressure difference stays well within the limit
of 3 mbar.
Slip coupling
SE405 Akavent Aerator
110mm
Underground pipe
Marley dBlue acoustic system
The Marley dBlue acoustic system is a 2 pipe clip diameters*: Secure fixing to the
triple-layer drainage system designed for 50 mm building’s structure.
use where improved levels of soundproofing 110 mm Elimination of the acoustic bridge
between the soil stack and the
are required. Suitable for use in domestic building’s structure
Now available from applications as well as hospitals and hotels,
where reduced noise levels are required.
Solvent waste Push-fit waste Overflow Compression waste Traps Used in conjunction with the acoustic pipe Pipe clip fastening
PVCu ABS Polypropylene PVCu Polypropylene Polypropylene clips, the dBlue system is designed to reduce
noise and acoustic vibrations to a level of 19dB
at 4 l/s discharge rate. It is also lightweight,
resistant to temperature change and is jointed
using the push-fit ring seal method.
The dBlue system is available in 40mm, 50mm,
110mm and 160mm diameters. It is also
compatible with the Marley PVCu soil and waste Acoustic inlays
system for branch connections. Suppression of vibrations between the system section
S uitable for internal Lightweight and cost F or internal use, complete range of
A ulti-fit compression
M range of traps, which
A Three contact surfaces with the pipe
*40 mm and 160 mm pipe clips also available. Special structure on the noise suppression surfaces
and external effective for internal ideally suited to fast pipework and fittings socket, for internal enable quick & easy
applications. installation. Easy to installation. Cost for overflow and use. Easy installation installation to any new
cut joint and install. effective solution where boiler condensate to similar sized new or existing plastic or
systems are being applications. or existing plastic and copper pipework.
installed or modified. copper pipework. Solvent soil
Available in Available in Available in Available in Available in Available in The Marley PVCu soil range has been of 4 top and 4 side entries, allowing for
32, 40 and 50 mm 32, 40 and 50 mm 32, 40 mm 21.5 mm 32, 40 mm 32, 40 and 50 mm extended with the addition of nine 110mm multiple inlet connections. At just 70mm
White & Black White, Black & Grey White, Black & Grey White White & Chrome White & Chrome solvent fittings, offering further options for above the floor slab, the manifold sits
the installer. The range includes the new neatly at finished floor level in most typical
ABS and polypropylene waste pipes and fittings are designed for internal use and should not be fitted externally as they will be subject to ultraviolet light 8-way soil manifold which offers the flexibility applications.
degradation. If fitted externally it is recommended that they are protected by the application of a suitable paint or are boxed in.
4 | MARLEY Soil & Waste Systems MARLEY Soil & Waste Systems | 5
Key components
The Marley soil & waste range offers an extensive choice of standard fittings for
commercial and domestic projects. PVCu Soil – Push-fit
Pictured is a selection of key components within the range. Product specification information on the PVCu, HDPE drainage and dBlue acoustic soil
or solvent weld
ranges is available as a separate document. All documentation can be downloaded from marleypd.co.uk
Marley co-ex soil The collar boss offers the flexibility of 4 top
and 4 side entries, allowing multiple inlet
connections. Specifically designed to prevent
Available in 82, 110 and 160mm and can
be adjusted by cutting the fitting at the
required angle and solvent welding the two
The Marley range offers a quick,
straightforward solution. In up to three
colour variants, pipe with a socket or
cross-flow and to allow multiple low level bath sections together.
110mm soil pipe with at least 30% recycled content or shower waste pipes to be connected to the
stack above floor level.
spigot end and a wide range of fittings.
Ideally suited for domestic and small
Code Angle achieved commercial applications.
SB37
Marley 110mm soil pipe now combines the environmental SB46
11° – 87½°
5° – 14°
benefits of using recycled material with the quality and SB47 21° – 90°
SB67 15° – 90°
aesthetic advantages of co-extrusion technology.
• BS EN 1329 certified
• Looks better, with higher gloss levels
• Has improved weathering performance
• Available in grey and black colour only
• Same list price as standard white pipe
• Colour matched to all standard 110mm Marley soil fittings
6 | MARLEY Soil & Waste Systems All documentation is available to download from marley.co.uk Technical hotline: 01622 852695 MARLEY Soil & Waste Systems | 7
Design
Methods of jointing
SWS415/41
While the principal method of jointing 82, 110 and 160mm PVCu pipes and fittings is push-fit, many boss pipe
components in the PCVu range are also available with sockets that allow for solvent weld jointing. Branches at the base of stacks
This particular technique is widely used on smaller diameter waste and overflow pipework although solvent
expansion and copper adaptor couplings include a push-fit joint to allow for thermal movement. weld joint
For single dwellings up to three storeys high, the distance between the
centre line of the lowest branch connection and the invert of the drain
As polypropylene cannot be solvent welded, the push-fit method of jointing is used throughout should be at least 450mm. For multi-storey systems up to five storeys
the system. high, the minimum distance should be 740mm and for systems higher
Marley dBlue is a push-fit acoustic drainage system push-fit than five floors no connections are permissible at ground floor level.
joint Where this occurs a separate stub stack should be provided to serve the UBL488 or
HDPE can be jointed using one of the following methods: Electrofusion; Butt welding; Plug in, ground floor or individual appliances should have their own separate 2 – UB455 bends
L
expansion or flange joints. connection to the building drain.
Thermal movement
The coefficient of linear expansion for PVCu is 0.06mm/m/°C. As a result a 3m length of
pipe will increase in length by approximately 3.6mm when subjected to a 20°C temperature
variation. Therefore, it is important to ensure that any movement is controlled and push-fit L = 450mm up to three storeys high
joints are installed to accommodate any expansion that may occur due to increases in ambient L = 740mm up to five storeys high
temperature or hot water discharges. L = one storey height, over five storeys
Soil stack capacity The table right details the important dimensions and weights of each Soil PVCu
of the systems together with the relevant British and European Standard. BS 4514 82 82.4 82.8 3.20 1.30
The capacity of a soil stack can be increased by the installation of a secondary ventilated stack. The All pipes are manufactured using a continuous extrusion process and
following information is taken from tables 11 & 12 of BS EN 12056-2: 2000 which illustrates this increase. BS EN 1329 110 110.0 110.3 3.20 1.70
fittings are produced by high-pressure injection moulding.
160 160.0 160.4 3.20 2.50
Waste 36/1¼ 36.10 36.50 1.80 0.33
Chemical and temperature resistance PVC-c 43/1½ 42.70 43.10 1.80 0.41
Primary ventilated stack Secondary ventilated stack Most plastics used for sanitary pipework are highly resistant to those BS EN 1566 55/2 55.70 56.10 1.80 0.57
Stack size Maximum capacity (l/s) Stack size Secondary vent Maximum capacity (l/s) chemicals normally found in domestic waste water and sewerage systems. Waste 36/1¼ 36.10 36.50 1.80 0.20
For applications where chemical discharges are likely to occur, the Marley ABS 43/1½ 42.70 43.10 1.80 0.26
(mm) Swept entries (mm) (mm) Swept entries Akatherm HDPE drainage range may be more suitable. BS EN 1455-1 55/2 55.70 56.10 1.80 0.35
82 2.6 82 50 3.4 Generally the maximum working temperature of Marley PVCu, dBlue Waste
110 5.2 110 50 7.3 & HDPE soil and waste systems when subjected to continuous flow is Polypropylene 34/1¼ 34.40 34.80 1.80 0.21
160 12.4 160 80 18.3 70°C and 75°C respectively. Higher intermittent discharges of up to BS EN 1451 41/1½ 40.80 41.20 1.80 0.26
95°C may be accommodated by PVCu, dBlue & HDPE provided the Overflow
period of discharge does not exceed one minute duration.
PVCu 21.5/¾ 21.55 21.70 1.10 0.11
Alternatively, reference can be made to ISO publications TR10358 BS EN 806-4
& TR7620 which provide comprehensive information on chemical
Secondary ventilated stack
and temperature resistance of plastics and rubber materials.
8 | MARLEY Soil & Waste Systems All documentation is available to download from marley.co.uk Technical hotline: 01622 852695 MARLEY Soil & Waste Systems | 9
Design
Offsets in stacks Stub stacks 8-way collar boss Branch pipe gradients
Offsets in the wet portion of a discharge stack An unventilated stub stack terminated with an The gradient of a branch pipe should be
should be avoided wherever possible but access fitting may be used to connect a group uniform and adequate to drain the pipe and
where they have to be fitted a large radius or of ground floor appliances to the building drain appliance efficiently. A minimum gradient of
SY401 Equal Branch
two 45° bends should be used to create each provided the vertical drop to the invert level 18mm/metre should be adopted for 32, 40 and
The maximum lengths given above may be increased where the branch pipe is ventilated or an air admittance valve is used. For further details refer to
the above standard.
Prevention of cross-flow To prevent cross-flow from a large diameter The Marley Collar Boss was specifically designed to overcome installation problems imposed
branch to a smaller waste connection, the latter by the 200mm restricted zone and to allow multiple low level bath or shower waste pipes to be
Where small diameter branch waste pipes
should be made to the stack at or above the connected to the stack above floor level. Cross-flow is prevented as the circular annular chamber
connect to a discharge stack they must be
centre line of the larger protects the small diameter waste connections from the WC discharge allowing waste water to
arranged to eliminate the risk of cross-flow from
branch, at right angles or flow freely and merge below the critical zone.
one branch to the other. A branch creates a
at least 200mm below the
no entry zone for opposing waste connections, Different combinations of 110mm branches can be used with the collar boss to accommodate
restricted zone. Entry is
which varies depending on the stack diameter. various WC positions which may be up to 3 metres from the vertical stack. SY401
permissible on the boundary
No connections should be made within the branch
SWS40 centre line directly opposite
restricted zone although entry is permissible
boss pipe or at right angles.
on the centre line of the boundary directly
opposite or at right angles.
H
Stack size Height of zone 'H'
H
(mm) (mm)
SA421 SCB41
boss adaptor SY405 collar boss
82 90 branch
SA421
110 110 boss connector
160 250
10 | MARLEY Soil & Waste Systems MARLEY Soil & Waste Systems | 11
Design
190mm
Now available from
P1940 low
level trap 110mm float at
KT21W entry tee
SWS41 9mm/metre fall SY401/SY405
KBA22W branch
bath/ boss pipe
45º bend
shower
A
40mm
500mm min
SM42W
adjustable bend
30
215mm minimum
35
duct width B
Manifold branch SM41W with SM42W Adjustable wall fixing
Manifold branch SM41W with SM43W
Cut line 50° 55° 60° 65° 70° 75° 80° 85° 90° Cut line SA323W 50° 55° 60° 65° 70° 75° 80° 85° 90°
cap & seal
Flush plate
A – projection (mm) 93 93 92 91 90 87 84 80 75 A – projection (mm) 180 180 179 178 177 174 171 167 162
W.C. cistern SM41W
B – drop (mm) 69 77 85 93 101 109 116 123 130 B – drop (mm) 69 77 85 93 manifold
101 109 116 123branch
130
front panel
W.C. frame
30
35
30
B
bracket with SC621 B
barrel clip collar
SA323W
SA323W SM41W
SA323W
SA323W capcap & seal
& seal SM44W
cap
cap&&seal
seal manifold
110 x 90mm branch SM41W Adjustable bend SM42W with socket SM41W JB42 two peice pipe bracket Adjustable bend SM42W with socket pan connector branch
trimmed to suit 50mm pan spigot manifold with SC621 barrel clip collar trimmed to suit 50mm pan spigot SM44W
SM41W
branch pan connector SM41W
manifold branch manifold branch
12 | MARLEY Soil & Waste Systems MARLEY Soil & Waste Systems | 13
Design
40mm dia
BATH/SHOWER SYS415
87.5° Branch
UFC SFC44 SFW44 SFC44 SFW44
P1940 KBA22
Universal fire collar pipe wrap fire sleeve pipe wrap
low level 'p' trap 45º bend
40mm dia fire collar
F.F.L.
Universal fire collar Fire collar Pipe wrap Fire collar Pipe wrap
KT21 2no 45° Bend SA421 SCBL41 fixed to soffit of fixed to soffit of fixed within concrete floor fixed to exposed side of fixed within fire
45º tee KBA22/KB22 Boss connector Collar boss
concrete floor concrete floor fire compartment wall compartment wall
14 | MARLEY Soil & Waste Systems MARLEY Soil & Waste Systems | 15
Installation data
Jointing techniques
The ring seal has been successfully employed as Solvent soil stack installation Push-fit soil stack installation
the principal method of jointing large diameter
The addition of the SE409 ring seal adaptor allows for thermal
PVCu pipes and fittings since their introduction
movement required in a solvent soil installation
over thirty years ago. This particular technique
has proved extremely reliable as the joint can
accommodate thermal movement that will
occur as a result of temperature variations. An SES401 SC41
expansion gap of between 5-10mm should be Double solvent coupling Socket/support clip
SC41 Anchor point
allowed within each ring seal socket as each full SES401
Socket/support clip SC41
length of pipe is installed and fixed using socket Double point
Anchor solvent coupling Socket/support clip
SC41 Anchor point
and barrel pipe clips. Socket/support clip
Anchor point
Solvent weld jointing is also widely used and
many components in the range are available
with this facility to provide an effective
alternative. By selecting these fittings a solvent
weld system can be installed, however, ring
seal joints must be incorporated to control
thermal movement.
While the most popular method of jointing
MAX 2000mm
MAX 2000mm
larger size PVCu pipes and fittings is by ring
seal, with small diameter waste pipework the ring seal joint solvent weld joint
MAX 2000mm
MAX 2000mm
principal choice is usually solvent weld. Where
this technique is used expansion couplings
must be introduced where pipe lengths exceed
2 metres or between fixed points. The same
40mm waste pipe expansion coupling KEC2
principle should also be adopted when the
polypropylene push-fit waste system is installed.
It should be noted that polypropylene cannot SFS41 SFS41
Access pipe Access pipe
be solvent welded and together with the ABS
waste system must not be fitted externally SFS41 SFS41
Access pipe Access pipe
unless painted to protect it from ultra-violet pipe clips
degradation.
5 to 10mm 5 to 10mm
Expansion gap Expansion gap
SC45 SC45
Pipe/barrel clip 5 to 10mm Pipe/barrel clip
5 to 10mm
Guide bracket Expansion gap Guide bracket
Pipe support Expansion gap SC45
SE409
Pipe/barrel clip
SC45
Pipe/barrel clip
Experience has proved that an efficient and Ring
Guideseal adaptor
bracket Guide bracket
reliable PVCu sanitary pipework system depends SE409
SYS405 SY401
Connection Connection
considerably on the attention that is placed from W.C
Ring sealbranch
110mm adaptor
from W.C
110mm branch
on the correct provision of pipe support SCB41
SYS405 SC41SY401
Connection Connection
brackets. This is particularly important in multi- Connection from
from W.C
Collar boss branch
110mm Connection from
from W.C
Collar boss branch
110mm
bath/shower bath/shower
storey buildings where care must be taken to SCB41 SC41
ensure clips are positioned to control thermal Connection from Collar boss Connection from Collar boss
bath/shower bath/shower
movement at each floor level.
Plastic coated metal socket clips are designed
to fit ring seal sockets and act as anchor
brackets. These used in conjunction with PVCu
intermediate pipe clips, control expansion and
contraction and maintain the vertical alignment
of the stack.
Pipe material BS Nominal pipe size Horizontal support (m) Vertical support (m)
Two piece socket clips SC41/61 may be adapted
to suit the appropriate pipe size by using a
section of barrel clip collar SC621 to provide PVCu 21.5 0.50 1.20
the necessary spacer sleeve. The table opposite Polypropylene 32 0.50 1.20
indicates the maximum recommended support 40 0.50 1.20
centres of different size plastic pipe systems. PVCc 32 0.50 1.20
barrel pipe clip SC45 socket pipe clip SC41
ABS 40 0.50 1.20
50 0.60 1.20
PVCu 82 1.00 2.00
110 1.00 2.00
160 1.20 2.00
16 | MARLEY Soil & Waste Systems MARLEY Soil & Waste Systems | 17
Installation data
Single support
Recommended for waste or larger diameter pipework fixed within 500mm of the floor soffit.
see table
Double support
Drill holes applicable for the diameter of the Developed for use with larger diameter pipework fixed within 1.0m of the floor soffit. angle brace
Vertical pipes
The transition between vertical and horizontal pipework should be achieved using two 45° bends
or a single 87½° long radius bend with a support bracket positioned as close as possible.
Branch connections
All branch connections into horizontal pipework should be made at 45° to ensure the discharge is 1.2m max.
swept in the direction of flow.
angle brace
Structural fixings
Put the pipe or fitting inside the pipe clip under
socket and connect the two parts of the open It is recommended that 6mm rawlbolt or similar proprietary fixings are used to secure base 750mm
plate max.
or 1.0m with
pipe clip with a drill. and angle cleats to the structure. side bracing
intermediate
bracket 110mm pipe
anchor bracket
1.0m
intermediate bracket
intermediate bracket
To connect a Marley dBlue soil stack to To connect a Marley dBlue soil stack to
Marley dBlue waste pipe, use the SA421BL Marley ABS & PVCc waste systems use
(40mm) or SA420BL (50mm) the SA411 (32mm), SA421 (40mm) or
SA420 (50mm) in white, black or grey.
1.2m max.
angle brace
18 | MARLEY Soil & Waste Systems MARLEY Soil & Waste Systems | 19
Installation data
Boss branches
The Marley range of five boss branches 110mm SWCB
32, 40 or SA411/421/420 ST40W 110mm
push-
are designed to allow multiple waste pipe 50mm pipe boss connector solvent
conn
connections to be made to the discharge WC connector
stack from different directions. Four different
side entry combinations are possible together
with a rear if required. Staggered waste
pipe connections, directly opposite are not
permitted as cross-flow could occur.
Compatibility
Boss pipes, boss connectors and strap-on
bosses fitted with multi-fit ‘T’ ring seals are
suitable for use with PVCc or ABS waste systems
WC connections 110mm ST40W
SWCB90
110mmSGS41W
Two different types of connectors are available push-fit WC
to BS EN 1566 or BS EN 1455-1, polypropylene solvent 110mm solvent connector 110mm
SY405 SA411/421/420 SY405 KBK25 or KBK35 to allow connection to vitreous china or stainless WC connector WC connector
to BS EN 1451-1 and metric size copper to branch boss connector branch knuckle bend
BS EN 16090. steel WC pans, slop hoppers and other similar
sanitary equipment. Manufactured in PVC and
Un-perforated boss upstands on boss pipes, eva (ethylene vinyl acetate) to accommodate a
branches and reducers may be drilled to accept range of outlet sizes between 84 and 110mm
32, 40 and 50mm boss connectors SA411, SA411/421/420 SA411/421/420
sanitary pipework or undergound drainage.
boss connector boss connector SWC11
SA421 and SA420 using a 51mm diameter hole SA323W push-f
saw. Knuckle bends KBK25 and KBK35 may also The 90º ST40W, ST41W and SG40W connectors WC seal and WC co
be used as 90° boss connectors for 40 and are supplied complete with flexible seal and retaining cap
50mm PVCc or ABS waste pipework. retaining cap. Where the SGS41W or STS41W
pan connectors are used, the WC socket must be
trimmed to suit the length of pan spigot before
Horizontal connections the SA323W is solvent welded in position.
SGS41W
110mm solvent 110mm
The SWS4135 boss pipe is recommended for WC connector
Ground floor toilets often have their own
use in horizontal situations where connections
connection to the building drain to eliminate
to 110mm diameter pipe is made at 45°. This
pipework and ducting. Where this occurs both
fitting has a 50mm solvent weld socket to SWCB90
types of connector are suitable for push-fit or 110mm ST40W 110mm
accept PVCc or ABS waste pipes. push-fit WC
solvent weld jointing to the 110mm PVC drain. solvent
connector
WC connector
SWC11
SY405 SY405 32, 40 or
SA323W push-fit
branch branch 50mm pipe WC seal and WC connector
retaining cap
110mm SWCB90
ST40W 110mm
push-fit WC
solvent ST40W SWCB90
Boss pipe connections WC connector
connector
solvent WC connector push-fit WC conne
Four different types of fitting are available to provide alternative methods of connecting small diameter waste pipes to 82, 110 and 160mm vertical
110mm SWCB90 SGS41W
discharge stacks. ST40W 110mm
push-fit WCsolvent
110mm 110mm
solvent
connector WC connector
110mm 110mm WC connector
Single boss pipes. Strap-on-bosses.
Available with ring seal or solvent Primarily designed to permit 32, 40
weld sockets for push-fit or solvent and 50mm waste pipe connections
weld jointing, single boss pipes to be made to existing 110mm PVCu
SWC11
allow 32, 40 and 50mm waste pipe discharge stacks, strap-on-bosses SA323W
110mm 11
push-fit
connections to be made at 87½° SWS415/ can also be used on new systems to SWS4150 PVCu drain PV
WC seal and WC connector
SWS41 /410/420 retaining cap
direct to the vertical stack. provide flexibility of installation during
SGS41W
different stages of construction. 110mm solvent 110mm ST40W SWCB90
110mm SWCB90 WC connector solvent WC connector push-fit WC connector
ST40W 110mm
push-fit WC
solvent
SW30/40 connector
82mm WC connector
boss branch SGS41W
Multiple entry boss pipes. Patch bosses. 110mm solvent 110mm
Supplied in ring seal or solvent weld Suitable for solvent weld jointing to WC connector
SA411/421/420 SWS332
options, all have 90° boss upstands boss connector new and existing 82mm diameter /340/350
SWC11
moulded on each fitting with one PVCu discharge stacks to accept SA323W push-fit
inlet port open. Connection is made 32, 40 and 50mm size PVCc or ABS WC seal and WC connector
using the appropriate size Marley waste pipework. retaining cap
boss connector to suit 32, 40 or SWC11 110mm 110mm
SA323W push-fit PVCu drain PVCu drain
50mm waste pipes. 32, 40 or 50mm pipe WC seal and WC connector
retaining cap
SGS41W
20 | MARLEY Soil & Waste Systems MARLEY Soil & Waste Systems | 21
110mm solvent 110mm
WC connector
Installation data
Site Work
Dimension (*) based on 230mm centre outlet WC pans and SM43W adjustable spigot bends cut to the angles shown.
Storage
Pipes should be stacked on a reasonably flat, sockets at alternate ends protruding to ensure
level surface on timber battens not less than pipes are evenly supported along their length.
75mm wide spaced at a maximum of 1m
Pipes should not be stacked more than 7 high
1. Select the adjustable bend angle required 2. File away any rough edges from the face 3. Apply a uniform coat of Marley solvent centres. Side support should also be provided
and when stored in the open for long periods,
from the above diagram according to the of the fitting and wipe clean the bend and cement, to the short branch radial at intervals of not more than 1.5m.
or exposed to strong sunlight, they should be
WC position. Cut the bend with a hacksaw, branch, with a dry cloth. Before jointing, socket and to the external surface of
Different size pipes should be stacked separately. covered with an opaque sheet. Fittings supplied
removing the unwanted portion.
the bend and branch should be checked for the bend body.
However, where this is not possible, larger in cardboard boxes or polythene bags should
position and alignment, both parts being
diameter pipes should be placed at the bottom. be stored under cover and kept packed until
marked to ensure accurate assembly.
required. Solvent cement should be stored in a
Spigot and socket pipes should be stacked
cool place out of direct sunlight and away from
SM41 separately. However, where this is not possible,
any heat source.
larger diameter pipes should be stacked with
SM42/SM43 SM42/SM43
SM42/SM43
4. Assemble the branch immediately, insuring 5. Trim the WC socket to suit the toilet pan To accommodate varying dimensions between
that the marked lines on the fitting coincide. spigot length and remove any swarf with the WC spigot and the centre line of the
Do not twist the two parts of the branch a file. Place the seal in the socket, apply a horizontal pipe run, the adjustable spigot bend
during this operation, but maintain steady uniform coat of solvent cement about 15mm SM43 or extension pipe SM45 can be used with
pressure until the spigot of the bend comes wide to the outside of the socket and inside WC connector SM44.
to rest against the internal surface of the the retaining cap. Push onto the socket and
branch socket. Quickly wipe off any surplus wipe off any surplus solvent cement.
solvent cement from the inside and outside
of the completed joint and hold in position
for approximately 15 seconds. Packing, storage and transportation specific to Marley dBlue
In order to facilitate transport and storage, Never throw, drag or bend pipes and fittings
SM41 all the fittings are packed in cardboard boxes. when unloading them.
SM41
Pipes are packed in bundles on pallets.
Pipes should be stored horizontally on even
Marley dBlue pipes and fittings must not be surfaces up to 1.5m high. All products should
SA323
cap and seal
transported unpacked (in bulk) along with be protected against sunlight.
other construction materials to prevent
Their outdoor storage time should not exceed
damage during transportation. The pipes
12 months.
SM42/SM43 must be transported in a horizontal position.
SM42/SM43
During unloading they must be protected
against damage, particularly at temperatures
below freezing.
22 | MARLEY Soil & Waste Systems MARLEY Soil & Waste Systems | 23
HDPE jointing methods
Electrofusion Jointing procedure 7. Prevent misalignment Butt-welding
1. Cut the pipe square
The pipe ends must be cut square to ensure that the heating element
✗
✔
vertical
down when installed
8. Prevent coupler from sliding
✗ KG
2. Mark insertion depth + 10 mm Butt-welding is a very economical and reliable jointing technique for
KG making welded joints, requiring only butt-welding equipment.
Electrofusion, the most simple and rapid jointing technique, is mainly
used on construction sites for a highly efficient method of assembly for This is to ensure that across the full welding zone the oxidised
layer All Akatherm pipes and fittings can be joined by this welding method.
will be removed.
pipes, fittings and prefabricated sections.
Fittings for which a k-dimension is shown in the table can be shortened
by not more than this amount. Butt-welding is extremely suitable for
Electrofusion couplers ✔ 10 mm prefabricating pipe sections and for making special fittings.
The PE range includes couplers in the diameters 40 to 315 mm. The
10 mm Preparations
couplers are extremely suitable for applications in waste water and
rainwater drainage, with the following features: 2x
The following guidelines are of importance when making a proper
butt-weld:
1. Injection molded with excellent dimensional accuracy and stability.
3. Scrape pipe and mark
10 mm insertion depth again
2. One welding indicator on each welding surface for checking both
The outer surface of the pipe (approx. 0.2 mm deep) must be
scraped
●● E stablish a work space where the jointing can be done without being
welding connections. 10 mm effected by major weather conditions.
for the full distance
10 mmthat will be covered by the coupler to remove any 9. Prevent load on vertical pipesystem
3. Centre stops easy to remove in order to use the coupler as a slide- 10 mm
surface 'oxidation'. ●● C
heck the equipment functions properly. Welding equipment used
over coupler.
The insertion depth should be marked again to safeguard full insertion.
✗ 2x
on site deserves special attention.
4. Resistance wires fixed to the surface for an optimal heat transfer ●● T he fittings and or pipes need to be aligned in the welding machine.
KG
and therefore a high quality welding connection. Mis-alignment can be up to 10% of the wall thickness.
✔
5. Yellow edge surrounding the welding indicators of the diameters ●● C
lean the heating element before each jointing operation with a lint-
200, 250 and 315 mm for better visibility. free cloth and suitable cleaner (see instructions welding machine).
●● Cut the pipe and/or fitting with a pipe cutter to make the end square.
Electrofusion control box
The Akafusion control box CB315 can not only weld Akatherm electro- ●● M
ake sure that once the pipe and/or fitting ends have been
fusion couplers in the diameter range 40 to 160 mm but also the 4. Clean coupler machined, they do not get dirty. Do not touch them with your hands.
diameters 200, 250 and 315 mm. The new techniques applied in the The surface needs to be clear of oil, grease and dirt.
electronics (such as integrated circuit boards) and the case material Before assembling the pipes into the coupler ensure that all surfaces
●● P ut the pipe parts into the welding machine to facilitate a firm hold
make it a solid and reliable control box. are clean and dry.
during the jointing process.
Multiple welding
✔ After connecting the cables of the control box the welding process ●● A
digital thermometer can be used to check the temperature of
can be commenced42
by pushing the start button. The CB315 control the heating plate. The temperature should be checked at several
box adapts the welding time to the ambient temperature. When it is points around the plate and should be between 200ºC and 220ºC.
colder than 20°C the welding time is extended and
2x when the ambient Maximum deviation between points is given in the table.
temperature exceeds 20°C the welding time is shortened. For welding
times and cooling down time seetable below.
5. Insert pipe and/or fitting up to pipe stop
Ensure that the pipe is pushed as straight as possible into the fitting.
The joint assembly should not be disturbed during the fusion cycle and
for the specified cooling time afterwards. KG
The CB315 is capable of welding several electrofusion couplers dimension d1 system cooling time d1 = 40-160 8ºC
simultaneously in the same time that is needed for producing one time
d1 = 200-315 10ºC
mm sec min
electrofusion weld. The combined diameters of the couplers to be
joined should not exceed 200 mm. For example in the case of a 45° 40-160 Constant current 5A 80 20
75/50 mm tee, both the diameters 75 mm and the branch 50 mm can Constant voltage
200-315 420 30
be welded at once. 6. Prevent joint movement during welding 220V
Maximum temperature variation heating element
✗
10. Don't weld coupler
42
twice
✗ 2x
24 | MARLEY Soil & Waste Systems MARLEY Soil & Waste Systems | 25
HDPE jointing methods
Welding process
The butt-welding of Akatherm HDPE operates according to the pressure N/mm2
following steps:
(PE)
HDPE
preheating pressure (F o) welding pressure (F L)
Machining the surface Heating up with less pressure
0,15
Both sides should be machined until they run parallel. When the machining
HDPE is a good insulator, therefore at this stage it is necessary that the
is finished, open the carriages (the plastic shavings must be continuous and
correct heating depth of the pipe ends is obtained. Only a small amount of
uniform in both sides to weld). Take off the milling cutter.
pressure 0.01 N/mm2 is required to maintain the contact of the pipe ends
Verify the alignment between the machined surfaces. Remove the plastic with the heating element. The heat will gradually spread through the pipe/
shaving. Do not dirty or touch the machined surfaces. fitting end. The size of the bead will increase a little. The time and pressure
needed for this phase can be found in the table on the next page.
heating pressure (F d)
0,01
time
pressure time
changeover
building-up
time
preheating time heating time cooling time
Machining the surface
40 3.0 55 4 0.2 29 4 4 4
Welding and cooling 50 3.0 70 5 0.5 30 4 4 4
56 3.0 75 5 0.5 30 4 4 4
After the jointing areas have made contact they should be joined with a
gradual increase in pressure up to the specified value. Keep the specified 63 3.0 85 6 0.5 31 4 4 4
welding pressure at a constant level during the cooling period. Do not 75 3.0 105 7 0.5 32 5 5 4
Preheating under pressure 90 3.5 145 10 0.5 35 5 5 4
cool artificially.
110 4.2 210 14 0.5 42 5 5 6
125 4.8 275 18 1.0 48 5 5 6
160 6.2 450 30 1.0 62 6 6 9
110 3.4 175 12 0.5 35 5 5 4
125 3.9 225 15 0.5 39 5 5 5
160 4.9 370 25 1.0 49 5 5 7
200 6.2 570 38 1.0 62 6 6 9
250 7.8 900 60 1.5 77 6 6 11
315 9.7 1400 93 1.5 77 6 6 11
200 7.7 700 47 1.5 77 6 6 11
250 9.6 1090 73 1.5 97 7 7 13
Welding and cooling 315 12.1 1730 115 2.0 121 6 8 16
The welded components can be removed from the machine when 50% of Welding parameters Akatherm HDPE drainage
the cooling period has elapsed, providing that this is done carefully, with
no load or strain being placed on the joint. The joint must then be left
undisturbed for the remainder of the cooling period.
In this table the welding parameters can be found for Akatherm HDPE.
The exact regulation of the welding machine depends on its mechanical
resistance. The tables provided with the machine are to be used for
regulating the machine.
26 | MARLEY Soil & Waste Systems MARLEY Soil & Waste Systems | 27
HDPE jointing methods
In the next illustration a good weld is shown with a uniform welding bead.
Jointing process: Jointing process:
At a visual inspection this would be classified as an "acceptable" weld.
Cut pipe square and remove burr Cut pipe square and remove burr
Butt-weld with even welding beads (acceptable)
✔
Mark insertion depth Mark insertion depth
Mis-alignment between fittings and pipe can occur for several reasons. ✔ ✔
Oval pipe ends or irregular necking of the pipe can cause an incomplete fit. Plug in socket: An expansion socket counteracts
If this is less than 10% of the wall thickness the weld can still be clas- sified the variation in length caused by the
as "acceptable"(see next illustration). The pipe needs to be inserted in thermal expansion and shrinkage of
the plug in socket using the full the pipe.
Butt-weld with mis-alignment of pipe (acceptable) insertion depth.
Depending on the ambient
✔ A plug-in joint is not to be used to temperature the insertion depth
accommodate the expansion and varies. The right insertion depth
contraction of a pipe system. for both 0°C and 20°C is indicated
on the expansion socket.
✔
Make joint
Make joint
Lubricate the pipe end and insert the pipe up to the marked
insertion depth. Lubricate the pipe end and insert the pipe up to the marked
insertion depth.
28 | MARLEY Soil & Waste Systems MARLEY Soil & Waste Systems | 29
HDPE jointing methods HDPE installation
Flange joint Contraction sleeve Tempered Pipe For the installation of Akatherm PE pipe systems several bracketing
The Marley Akatherm HDPE pipe is tempered. This pipe is produced systems can be used:
according to the standards EN 1519 and ISO 8770 but has undergone a
heat treatment after extrusion. The result is less shrinkage when cooled Anchor point bracket
down from high operational temperature. This gives less stress on joints This method of bracketing is used for rigid installations. The expansion
resulting in a longer life for the pipe system. forces are transferred to the building structure.
The flanged joint is a detachable joint not that common in soil and waste
systems. It is the ideal jointing method to connect the system onto
flanged equipment and to install valves. The joint can be made by the
Support bracket fixed to building Electrofusion coupler either side of
following steps: structure- brackets must be of sufficient support bracket
strength to resist forces generated by
●● Mount backing ring over pipe or fitting Pipe length after production thermal movement of the PE pipes
●● Weld stub flange to fitting or pipe Anchor bracket with 2 electrofusion couplers Art. Nr. 41xx95
Linear expansion
●● Apply seal
The Marley Akatherm HDPE material has a linear expansion coefficient of
●● M
ount bolts, nuts and washers and tighten nuts with the bolt torque A simple transition to other materials than HDPE can be made using the 0.13-0.19 mm/mK. We calculate with an expansion of 0.2 mm per meter
mentioned in the next table. contraction sleeve. pipe for every °C temperature difference. The total length variation can Anchor bracket with expansion socket
be calculated as follows:
The sleeve provides a non pull-tight connection and is installed as follows: This method of installation is used for flexible installations where
d1 (mm) Bolt torque (Nm)
Δl = L x λ x Δt the expansion force is not transferred to the building structure.
●● Mark insertion depth on the connecting pipe. Only the force caused by the internal resistance of the expansion
40 20 Δl = length change in mm socket is transferred.
●● C
onnect contraction sleeve to HDPE pipe or fitting using
50 30 L = total length of pipe
electrofusion or butt fusion.
56 35 λ = linear expansion coefficient
●● Mount the O-ring in the middle of the insertion zone.
63 35 Δt = temperature difference in °C
75 40 ●● H
eat up the contraction sleeve evenly with a torch or an industrial
heater. Diameters above 125 mm are best heated up using a second Example:
90 40
heat source.
110 40 Pipe 10 metres with a maximum temperature of 60°C and a minimum
125 40 temperature of -20°C. This results in an expansion of:
160 60 Support bracket fixed to building Thermal movement of PE pipework
Δl = 10 x 0,2 x 80 = 160 mm structure-brackets to be of sufficient
200 70
strength to resist forces caused by the
250 80 Length changes can be accommodated by the expansion socket which internal resistance of the expansion socket
315 100 can take up the expansion and contraction of a 5 meter length of pipe
Anchor with expansion socket
for temperatures between -20°C and 70°C.
Guide bracket
30 | MARLEY Soil & Waste Systems MARLEY Soil & Waste Systems | 31
HDPE installation
Bracket distance Horizontal installation with expansion sockets Vertical installation: to the wall
The bracket distances for Akatherm PE pipes are largely dependent on and support trays For the vertical installation the bracketing
the working temperature of the pipe system. Also the filling rate of the In this kind of installation the pipe is extra supported by support trays. distance is in general 1,5 times the
pipe plays a role. A fully filled pipe has a different bracket distance. The distance between the brackets can be larger. The support shells are distance of the horizontal bracketing.
installed on to the pipe with straps. For distances see table below. There is no separate bracketing distance
for immediately in front of the expansion
socket because there is no sagging of the
pipe and the insertion is always in line.
d1 LA LA* LBA
Horizontal installation with expansion sockets without Bracket distances vertical installation with expansion sockets
support trays
The bracket directly in front of the expansion socket has a shorter
bracket distance (LA*) This makes a better guidance into the expansion d1 LA LA*
socket possible (see image). The bracketing distances for this application
can be found in table below. The maximum distance between 2 75 0.8 m 0.4 m
expansion sockets is 5 m.
90 0.9 m 0.5 m
110 1.1 m 0.6 m
125 1.3 m 0.7 m
160 1.6 m 0.8 m
200 2.0 m 1.0 m
250 2.0 m 1.0 m
315 2.0 m 1.0 m
32 | MARLEY Soil & Waste Systems MARLEY Soil & Waste Systems | 33
HDPE expansion socket insertion depths HDPE handling and storage
200mm Expansion Socket Pipe must be transported by a suitable vehicle and properly loaded and
(S402020) Without Protection Plug unloaded, e.g. wherever possible moved by hand or mechanical lifting
equipment. It must not be dragged across the ground. The storage
50mm Expansion
90mm Expansion Socket should be flat, level and free from sharp stones. Tools
Socket (S400520)
(S420920)* Tools need to be protected against moisture.
Bundles
Bundled packs of pipe should be stored on clear, level ground with the Health and safety at work act and COSHH regulations
battens supported from the outside by timber or concrete blocks. For Attention is drawn to the requirement in the UK of this act and to the
safety, bundled packs should not be stacked more than three high. 1988 Control of Substances Hazardous to Health (COSHH) Regulations.
Marley cannot accept responsibility for accidents arising from the misuse
Smaller pipes may be nested inside larger pipes. Side bracing should be
of its products because of bad installation or incorrect application.
provided to prevent stack collapse.
110mm Expansion Socket 56mm Expansion Handling of HDPE has no detrimental health impact. It is recommended,
Similar precautions should be taken with fittings and these should be
(S421120)* Socket (S405620) kept packaged until required for use.
however, that HDPE is not ingested or dust inhaled.
Physical contact
HDPE is not considered to be a skin irritant. Where HDPE dust is
generated by cutting of machining pipe of fittings, powder particles of
125mm Expansion Socket 63mm Expansion HDPE dust may cause eye irritation by abrasion.
(S421220)* Socket (S400620)
Butt Weld Only Behaviour in Fire
HDPE is a flammable material. It has, however, been installed throughout
Europe for over 35 years and presents no greater risk of fire propogation
than similar plastic based systems when installed in accordance with local
regulations. Marley Unicollar firecollars are suitable for use with Akatherm
HDPE (up to 200mm) and these should be installed in accordance with
the instructions provided.
315mm Expansion Socket 160mm Expansion Socket * Insertion depth and expansion
(S403120) Without Protection Plug (S421620)* details indicated on fitting
Lengths
HDPE Expansion Details Pipe lengths stored individually should be stacked in a pyramid not more
Type A Type B that one metre high, with the bottom layer fully restrained by wedges.
Min. Insertion
Diameter Total Length Max. Expansion (No White Retaining Ring) (With White Retaining Ring) Where possible, the bottom layer of pipes should be laid on timber
Depth @ 20°C
battens at one-metre centres. On site, pipes may be laid out individually
40mm 132mm 76mm 56mm Type B in strings (where appropriate, protective barriers should be placed with
50mm 132mm 76mm 56mm Type B adequate warning signs and lamps).
56mm 132mm 76mm 56mm Type B
63mm 132mm 76mm 56mm Type B
75mm – On Fitting On Fitting Type A
90mm – On Fitting On Fitting Type A
110mm – On Fitting On Fitting Type A
125mm – On Fitting On Fitting Type A
160mm – On Fitting On Fitting Type A
200mm 230mm 120mm 110mm Type A
250mm 250mm 125mm 125mm Type A
315mm 270mm 126mm 144mm Type A
34 | MARLEY Soil & Waste Systems MARLEY Soil & Waste Systems | 35
Standards Marley system solutions
Accreditations
ER INDUSTR
AT
TIFIE TO W
Y
SP
ECIFICAT
D
ON
I
C
Equator is ideal for hot & cold water or Alutec offer modern and traditional The Multikwik brand is known and trusted
Certificate No. 06/4325 BS EN 1329-1 : 2000 BS EN ISO 9001: 2008
BS 4514 : 2001 BS EN ISO 14001: 2004 central heating installations. A tamperproof aluminium rainwater profiles, providing by plumbers for its sanitary frames, cisterns,
BS EN 1566-1: 2000 fitting with a unique grip release mechanism solutions for any type of building. Aluminium traps, compression waste systems and
BS 5255: 1989
BS EN 1455-1: 2000 ensuring that the system can only be has high visual appeal and durability, lasting market leading range of pan connectors.
BS EN 1451-1: 2000
BS EN 1519-1: 2000 disassembled through the use of a special for 50 years or more. The product portfolio Complementing the Marley range it provides
de-mounting tool. Equator has been designed includes Evolve; easy to install, low cost gutter an excellent solution to modern bathroom
to meet the requirements of BS 7291: Parts 1 systems in four profiles. The rainwater ranges design with a wide choice of product options.
& 3; Class S. The complete Equator system is are complemented by aluminium soffit and
backed by a 30 year guarantee. fascia systems and roof & floor outlets.
36 | MARLEY Soil & Waste Systems MARLEY Soil & Waste Systems | 37
Notes Notes
marley.co.uk
For general enquiries and details of your
nearest stockist please call the customer
services department:
Tel: 01622 852585
email: [email protected]
To place an order
For delivery to England & Wales
Email: [email protected]
Fax: 01622 851111
For delivery to Scotland
Email: [email protected]
Fax: 01698 810307
Head Office
Lenham, Maidstone
Kent ME17 2DE
Tel: 01622 858888
Fax: 01622 858725
Scotland
Birkenshaw Industrial Estate
Uddingston, Glasgow G71 5PA
Tel: 01698 815231
Fax: 01698 810307
Export Division
Lenham, Maidstone
Kent ME17 2DE England
Tel: +44 (0)1622 858888
Fax: +44 (0)1622 850778
April 2014